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Case Study

How Kule Top Toys Doubled its PA-AMR Fleet in Just One Year

FlexSwift-MAX-in-Kule-Top-Toys

Units of AMR

+

Piece Per Hour / Person

%

Cost Reduced

%

Picking Accuracy

Project Overview

Kule Top Toys, a leading toy brand with over 10 million members and 300+ stores, transformed its 2,000 m² Ningbo distribution center with a two-phase approach to AMR deployment. Phase I (2022) introduced 20 Autonomous Mobile Robots (AMRs), while Phase II (early 2025) added another 20, doubling the original fleet to 40 AMRs. This automation now supports 10,000 units outbound daily and achieves 130 pieces per hour per person—a 40% boost in efficiency. It also reduces manual workload, stabilizes labor demands, and ensures near 100% inventory accuracy for both inbound put-away and outbound picking.

The Problem

Before implementing AMR, Kule Top Toys faced several challenges with their manual workflow. Limited picking capacity created bottlenecks, and worker fatigue led to noticeable drops in productivity each afternoon. Long-distance put-away tasks resulted in wasted travel time, and mismatched inbound and outbound cycles often caused inventory errors and stock shortages. These issues together hindered productivity and made it hard to keep up with increasing order volumes.

  1. Operational Efficiency Bottleneck: Manual picking capacity was capped at about 90+ pieces per person per hour, making it difficult to keep pace with rising order volumes.

  2. Worker Fatigue: Labor intensity—particularly for tasks requiring long walks with loads—led to a noticeable drop in productivity (10~20%) after 3:00 PM, contributing to higher turnover and training costs.

  3. Lengthy Non-Value-Added Paths: Put-away activities involved manual transport of goods from the receiving area to racks, often over distances exceeding 50 meters, resulting in significant wasted time and effort.

  4. Mismatched Inbound & Outbound Pace: Slow put-away cycles caused inaccuracies in inventory data, leading to frequent out-of-stock issues for pickers. This mismatch reduced overall warehouse throughput.

The Solution

To tackle these challenges, Kule Top Toys teamed up with Syrius Technology to deploy 40 AMRs that manage both inbound and outbound tasks at the same time.

  • Dual-Fleet Operation at One Site: One group of AMRs starts at the rack area, picking orders and delivering them to specific drop-off points. Another group begins at the temporary receiving/staging area, moves goods to the racks for storage, and then returns for more loads.
  • Collaborative Workflow: Operators work with AMRs to load, unload, and scan barcodes. This setup brings picking and storage tasks closer together, reducing unnecessary travel.
  • Random Storage: During storage, the Warehouse Management System (WMS) suggests the best rack spots. The AMR barcode scanners record SKU details and amounts, ensuring almost perfect inventory accuracy.
  • Scalability with RaaS (Robots as a Service): Syrius Technology and Kule Top Toys have a flexible rental agreement based on Robot-as-a-Service, allowing them to quickly add new AMRs in 1~2 hours if needed.
Kule-Top-Toys-Pick-Assist-Scenario
Kule-Top-Toys-Packing-Station

An AMR smoothly delivers a box of toys to an operator, who follows instructions to unload it. This efficient process, now routine, boosts productivity and eases heavy lifting. The AMR quickly moves on to its next task.

Kule-Top-Toys-Picking

In a narrow aisle, the AMR waits as the operator picks and scans items. After loading the robot, a chime and light confirm the load. The AMR then moves smoothly to the next stop in the warehouse.

Configuration Details

Software Configuration
  • HandyPage Applet: Installed on PDAs for each operator to make collaboration with AMRs easier.
  • SpeedPicker Applet: Installed on each AMR to assist with efficient picking tasks.
  • GoodsKeeper Applet: Used for managing storage and put-away tasks.
Systems
  • FlexGalaxy.AI: A unified platform that controls AMRs, equipment, user permissions, and task management.
  • TTX (通天晓) WMS: The current WMS integrated for real-time inventory updates and order processing.
Hardware Configuration
  • FlexSwift MAX AMR: Autonomous mobile robots with modular lift systems to handle different container heights.
  • FlexTray An adjustable tray that fits various tote sizes, perfect for small to medium-sized SKUs.

The Results

By using 40 AMRs to automate both incoming and outgoing tasks, Kule Top Toys greatly boosted efficiency and kept staffing levels steady:

  • Productivity Boost About 40% better efficiency in picking and storing items. Labor needs cut by one-third. 40% less time spent on unproductive travel; employees no longer need to carry heavy loads.
  • Better Inventory Accuracy Almost 100% accuracy thanks to AMR barcode scanning and WMS integration.
  • Complete Automation AMRs manage both storing and picking. Full integration with sorting systems and conveyors now streamlines the entire warehouse process.
  • Improved Workforce Stability Turnover among frontline workers dropped by 50% from the previous year. Less physical strain reduced errors and injuries related to fatigue.

Looking to 2025, Kule Top Toys plans to open more distribution centers and likely add 30~40 more AMRs, repeating the success seen in Ningbo.

 

Where are we now

Kule Top Toys has renewed its contract with Syrius Technology and plans to expand its use of AMR solutions to new locations.

Having successfully automated the Ningbo facility, Kule Top Toys and Syrius Technology have extended their RaaS agreement for another two years. Syrius Technology will also provide on-site planning for upcoming distribution centers, further optimizing layouts using an “AMR-first” approach. This method ensures that any new operations can quickly leverage robotic fleets to maximize efficiency and sustain Kule Top Toys’ ongoing growth.

Kule Top Toys

Services we provided:

  • On-Site AMR Deployment and Configuration

  • WMS Integration to FlexGalaxy.AI

  • New Warehouse Planning, Consulting, and Simulation

  • Robot-as-a-Service (RaaS)

 

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